Wrinkle free geometric opening in a vacuum insulated panel

ABSTRACT

At least one puck is used to manufacture a vacuum insulated panel with a shaped opening. A pair of barrier films are positioned about an insulated core having a shaped opening such as a through bore, cutout, or relief. The puck includes a protrusion having a shape similar to that of the opening of the insulated core. With the barrier films positioned about the insulated core, the pucks are inserted into the opening from opposite sides of the insulated core to thereby compress the barrier films between the shaped protrusions of the pucks to thereby prevent wrinkles and/or creases in the barrier films. The insulated core is then subjected to a vacuum to evacuate the insulated core of any gases and the barrier films are heat sealed to maintain the insulated core in the evacuated state. Excess barrier film is then removed to provide a wrinkle and/or crease free seal.

PRIORITY

This application claims priority to U.S. Non-Provisional patentapplication Ser. No. 14/178,335, entitled “Wrinkle Free GeometricOpening in a Vacuum Insulated Panel,” filed Feb. 12, 2014, which in turnclaims priority to U.S. Provisional Patent Application No. 61/763,537,entitled “Wrinkle Free Geometric Cutout by Means of Puck′/Filler Design,in a Vacuum Insulated Panel,” filed Feb. 12, 2013. The disclosures ofU.S. Non-Provisional patent application Ser. No. 14/178,335 and U.S.Provisional Patent Application No. 61/763,537 are incorporated byreference herein.

BACKGROUND

In the transporting or shipment of temperature sensitive materials oritems such as blood, plasma, vaccines and certain drugs, it is known touse insulated containers which include heating and/or cooling means asdisclosed, for example in U.S. Pat. No. 7,913,511, entitled “CargoContainer for Transporting Temperature Sensitive Items”, and issued Mar.29, 2011; in U.S. Pat. No. 5,950,450, entitled “Containment System forTransporting and Storing Temperature-Sensitive Materials”, and issuedSep. 14, 1999; in U.S. Pat. No. 5,943,876, entitled “Insulating VacuumPanel, Use of Such Panel as Insulating Media and Insulated ContainersEmploying Such Panel”, and issued Aug. 31, 1999; in U.S. Pat. No.5,483,799, entitled “Temperature Regulated Specimen Transporter”, andissued Jan. 16, 1996; and in U.S. Pat. No. 5,603,220, entitled“Electronically Controlled Container for Storing Temperature SensitiveMaterial”, and issued Feb. 18, 1997; the disclosures of which areincorporated by reference herein. When it is desirable to transport orship a larger volume of temperature sensitive items, it is desirable toprovide a cargo container which is adapted to receive a palletsupporting the temperature sensitive items and which also includescooling and/or heating means for maintaining the temperature sensitiveitems within a close predetermined temperature range. Such cargocontainers are disclosed, for example, in U.S. Pat. No. 5,187,947,entitled “Wheel Type Freezer and Method for Rapid, Low TemperatureFreezing”, and issued Feb. 23, 1993; and U.S. Pat. No. 6,860,115,entitled “Air-Cargo Container, a Refrigerator Unit for an Air-CargoContainer and a Manufacturing Method of an Air-Cargo Container”, andissued Mar. 1, 2005; and in a publication of applicants entitledAcuTemp™ Thermal Pallet Shipper; the disclosures of which areincorporated by reference herein. A Temperature-Controlled, Pallet-SizedShipping Container is also disclosed in U.S. Pat. Pub. No. 2004/0226309,published Nov. 18, 2004, and the disclosure of which is hereinincorporated by reference. This published application claims the benefitof Provisional Pat. Appl'n. No. 60/447,987, filed Feb. 17, 2003, and thedisclosure of which is incorporated by reference herein.

In any such cargo container adapted to receive one or more pallets oftemperature sensitive items, it may be desirable for the walls and thedoors of the cargo container to be insulated with a thermal insulationhaving a high R-value while minimizing the thickness of the walls andthe doors in order to maximize the cargo space and minimize heattransfer to and from the interior of the cargo container. One such typeof thermal insulation having a minimal thickness and a high R-value is avacuum insulated panel (“VIP”). VIPs are known in the art. VIPs may havean R-value between R-30 and R-50. VIPs are generally made by sealing apanel of thermal insulation in a barrier film while subjecting the panelto a vacuum, a process referred to as “evacuating.” The barrier film isformed into a pouch into which the panel of thermal insulation isinserted before the panel is evacuated. Upon being evacuated, the panelis contained within the barrier film in an evacuated state by heatsealing the barrier film.

A cargo container may include a rigid housing. The rigid housing maycomprise a rigid outer shell and a rigid inner shell. An interior space,into which flat panel insulation cartridges or cassettes may beinserted, is defined between the inner shell and the outer shell. Eachcassette includes one or more layers of VIPs which may be separated by afoam insulation sheet and sandwiched between corrugated protectiveplastic sheets, all of which are wrapped within a plastic film. Thecargo container may further include a refrigeration evaporator, anelectrical heating element, circulating fans, a refrigerationcompressor, storage batteries, and a control system. It may be desirableto provide through bores, cutouts, and/or reliefs within the VIPs suchthat refrigeration lines, electrical conduit, etc. may be passed therethrough or therein or such that the VIPs complement contours of theinner shell and/or outer shell. Other features and advantages of theinvention will be apparent from the following description, theaccompanying drawings, and the appended claims.

In certain instances, it may be desirable to provide VIPs with throughbores having particular geometric shapes. In such instances, a throughbore may be formed in the panel of thermal insulation prior to beinginserted into the film barrier and subject to evacuation. Once insertedinto the film barrier, the panel is evacuated which causes the barrierfilm to fill the void of the through bore in the panel at which time thebarrier film is heat sealed. The barrier film within the through boremay then be cut to the desired geometric shape thus defining a throughbore in the VIP. Such a method of forming a through bore may cause thebarrier film to gather within the void of the through bore and wrinkleand/or crease which can be detrimental the entire VIP. Thus it may bedesirable to develop a method of avoiding wrinkling and creasing of thebarrier film when forming through bores in VIPs.

It should be understood that the VIPs, and the methods of making VIPsdiscussed below, should not be construed as being limited to use withcargo containers, and may be used for any other purpose requiring use ofan insulating barrier. For instance, VIPs may be used to insulate hotwater heaters, refrigerators, freezers, ranges, and/or any otherappliance or device. VIPs may also be used to insulate duct, pipes,and/or tubes including, but not limited to, oil pipelines, hot/coldwater piping, and/or HVAC ducts. Additionally, VIPs may be used invehicles (cars, trucks, planes, boats, etc.) to insulate the passengercompartment, trunk, engine compartment, and/or any other part of thevehicle requiring insulation. Other uses for VIPs are well known in theart, and will be further appreciated from the teachings herein.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims which particularly pointout and distinctly claim this technology, it is believed this technologywill be better understood from the following description of certainexamples taken in conjunction with the accompanying drawings, in whichlike reference numerals identify the same elements and in which:

FIG. 1 depicts a perspective view of one of a pair of oblong-shapedpucks;

FIG. 2A depicts a perspective view of an insulated core having anoblong-shaped through bore;

FIG. 2B depicts a perspective view of the insulated core of FIG. 2A withbarrier film disposed about the insulated core;

FIG. 2C depicts a perspective view of the insulated core of FIG. 2A,with the barrier film of FIG. 2B disposed about the insulated core, andwith the pair of pucks of FIG. 1 disposed within the through bore of theinsulated core;

FIG. 3 depicts a cross-sectional view of the insulated core of FIG. 2A,with the barrier film of FIG. 2B disposed about the insulated core, andwith the pair of pucks of FIG. 1 disposed within the through bore of theinsulated core;

FIG. 4A depicts a perspective view of the insulated core of FIG. 2A,with the barrier film of FIG. 2B disposed about the insulated core, withthe pair of pucks of FIG. 1 disposed within the through bore of theinsulated core, with the insulated core having been exposed to a vacuum,and with the barrier film having been heat-sealed about the insulatedcore;

FIG. 4B depicts a perspective view of the insulated core of FIG. 2Aafter being subjected to a vacuum and having the barrier film of FIG. 2Bheat-sealed about the insulated core, with the pair of pucks of FIG. 1removed from the through bore of the insulated core;

FIG. 4C depicts a perspective view of the insulated core of FIG. 2Aafter being subjected to a vacuum and after having the barrier film ofFIG. 2B heat-sealed about the insulated core, with an excess of barrierfilm having been removed;

FIG. 5 depicts a perspective view of one of a pair of circle-shapedpucks;

FIG. 6 depicts a perspective view of one of a pair of trapezoid-shapedpucks;

FIG. 7A depicts a perspective view of an insulated core having a pair ofcircle-shaped through bores and a trapezoid-shaped relief;

FIG. 7B depicts a perspective view of the insulated core of FIG. 7A withbarrier film disposed about the insulated core;

FIG. 7C depicts a perspective view of the insulated core of FIG. 7A,with the barrier film of FIG. 7B disposed about the insulated core, andwith the pairs of pucks of FIGS. 5 and 6 disposed within the throughbores and relief of the insulated core;

FIG. 8 depicts a cross-sectional view of the insulated core of FIG. 7A,with the barrier film of FIG. 7B disposed about the insulated core, andwith the pairs of pucks of FIGS. 5 and 6 disposed within the throughbores and relief of the insulated core;

FIG. 9 depicts another cross-sectional view of the insulated core ofFIG. 7A, with the barrier film of FIG. 7B disposed about the insulatedcore, and with the pairs of pucks of FIGS. 5 and 6 disposed within thethrough bores and relief of the insulated core;

FIG. 10A depicts a perspective view of the insulated core of FIG. 7A,with the barrier film of FIG. 7B disposed about the insulated core, withthe pairs of pucks of FIGS. 5 and 6 disposed within the through boresand relief of the insulated core, with the insulated core having beenexposed to a vacuum, and with the barrier film having been heat-sealedabout the insulated core;

FIG. 10B depicts a perspective view of the insulated core of FIG. 7Aafter being subjected to a vacuum and after having the barrier film ofFIG. 7B heat-sealed about the insulated core, with the pairs pucks ofFIGS. 5 and 6 removed from the through bores and relief of the insulatedcore; and

FIG. 10C depicts a perspective view of the insulated core of FIG. 7Aafter being subjected to a vacuum and after having the barrier film ofFIG. 7B heat-sealed about the insulated core, with an excess of barrierfilm having been removed.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the technology may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presenttechnology, and together with the description serve to explain theprinciples of the technology; it being understood, however, that thistechnology is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the technology shouldnot be used to limit its scope. Other examples, features, aspects,embodiments, and advantages of the technology will become apparent tothose skilled in the art from the following description. As will berealized, the technology described herein is capable of other differentand obvious aspects, all without departing from the technology.Accordingly, the drawings and descriptions should be regarded asillustrative in nature and not restrictive.

It is further understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Thefollowing-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

At least some of the devices and/or methods discussed below may be usedto manufacture VIPs to be used in containers constructed in accordancewith, or such VIPs discussed below may themselves be constructed and/oroperable in accordance with, at least some of the teachings of U.S. Pat.No. 7,913,511; U.S. Pat. No. 5,950,450; U.S. Pat. No. 5,943,876; U.S.Pat. No. 5,483,799; U.S. Pat. No. 5,603,220; U.S. Pat. No. 5,187,947;U.S. Pat. No. 6,860,115; and/or U.S. Pat. Pub. No. 2004/0226309. Thedisclosures of each of the foregoing patents and publications areincorporated by reference herein. It should be understood that themethods discussed below may used to manufacture VIPs to be used in, orsuch VIPs discussed below may themselves be constructed and/or operablein accordance with VIPs of the CSafe® RKN containers, the CSafe SVScontainers, the CSafe AcuTemp AX27L containers, the CSafe AcuTemp AX56Lcontainers, the CSafe AcuTemp Courier containers, the CSafe AcuTemp PX1Lcontainers, or any other the CSafe packing container(s). Furthermore,the VIPs discussed below may have various structural and functionalsimilarities with those taught in any of the other references that arecited and incorporated by reference herein.

An improved method of manufacturing VIPs includes the following steps.First, providing an insulated core having one or more through bores,cutouts, and/or reliefs (hereinafter generally referred to as“openings”). The insulated core may comprise microporous open cellsilica aerogel, precipitated silica, fumed silica, glass fiber mats,ceramic fiber mats, and/or open-cell foam, but may comprise any otherheat resistant insulating material. As will be understood from thediscussion below, the insulated core and the openings formed therein maycomprise any shape. A pair of barrier films are disposed about a topsurface and a bottom surface of the insulated core to completely envelopthe insulated core, including the opening formed therein, between thebarrier films. Barrier films for use in VIPs are well-known in the art.The barrier films may comprise a multi-laminate oxygen and water vaporbarrier film, but may comprise any other appropriate barrier material.

With barrier films disposed about the insulated core, a first puck ispositioned within the opening of the insulated core from a top side ofthe insulated core, and a second puck is positioned within the openingof the insulated core from a bottom side of the insulated core tothereby capture the barrier films between the pair of pucks. The pucksmay comprise any material having sufficient rigidity, weight, andthermal resistance to withstand pressure, movement, and/or heat from“evacuating” and heat sealing the insulated core. As will be understoodfrom the discussion below, it may be desirable to provide pucks withmagnetic properties such that the pucks are attracted toward oneanother. The pucks may comprise a shape substantially similar to theshape of the opening of the insulated core, additionally oralternatively, the pucks may comprise protrusions having a shapesubstantially similar to the shape of the opening of the insulated coresuch that insertion of the pucks within the opening may compress thebarrier films between the pair of pucks, between the pair of pucks andan interior surface of the opening, and/or between the pair of pucks andthe top surface and the bottom surface of the insulated core.Compression of the barrier films in this manner is configured tominimize wrinkles and/or creases within the barrier films in thesecompressed areas.

At this point, the insulated core is subjected to a vacuum to “evacuate”the insulated core of any gases within any void spaces of the insulatedcore to thereby reduce potential heat transfer across the insulatedcore. As the insulated core is subjected to a vacuum, the barrier filmsare heat sealed around the perimeter of the insulated core to therebyfluidly seal the insulated core in the evacuated state. This evacuationand/or heat sealing may cause wrinkles and/or creases in barrier filmsparticularly around any opening, however, as discussed above, the pairof pucks are configured to minimize wrinkles and/or creases in thebarrier films within the above discussed opening. The pucks are thenremoved from the opening, and the barrier film within the opening isheat sealed. Finally, excess material of the barrier films is thenremoved to thereby define a substantially wrinkle and/or crease freeseal extending inwardly from the interior surface the opening.

I. Exemplary Puck to Reduce Wrinkles and/or Creases Within IP BarrierFilms

FIGS. 1-4C illustrate an exemplary puck (100) and method of using puck(100) to manufacture VIPs to avoid wrinkling and/or creasing of abarrier film used to enclose an insulated core. FIG. 1 shows a puck(100) having a base (102) and an oblong-shaped protrusion (104)extending from a top surface (103) of base (102). Base (102) comprises aplurality of through bores (106). Although puck (100) of the presentexample comprises an oblong-shaped protrusion (104), it will beappreciated from the discussion below that puck (100) may comprise aprotrusion having any other required shape (square, rectangular,triangular, etc.).

FIGS. 2A-4C show the steps required to manufacture a VIP (130) usingpuck (100). FIG. 2A shows a circular-shaped insulated core (110) havingan oblong-shaped through bore (112). Although insulated core (110) ofthe present example is circular-shaped, it should be understood thatinsulated core (110) may comprise any other required shape (square,rectangular, triangular, etc.). Also, although insulated core (110) ofthe present example comprises an oblong-shaped through bore (112), itwill be appreciated from the discussion below that through bore (112)may comprise any other required shape (square, rectangular, triangular,etc.). As shown in FIG. 2B, a pair of barrier films (120, 122) aredisposed adjacent to a top surface (114) and a bottom surface (116) ofinsulated core (110).

As shown in FIGS. 2C and 3, with barrier films (120, 122) disposedadjacent to top surface (114) and bottom surface (116) of insulated core(110), a first puck (100A), constructed according to the abovediscussion regarding puck (100) but referred to as first puck (100A) forthe sake of clarity, is positioned downwardly within through bore (112)such that top surface (103) of base (102) of first puck (100A) rests onor close to top surface (114) of insulated core (110) with barrier film(120) disposed there between. At the same time, a second puck (100B),constructed according to the above discussion regarding puck (100) butreferred to as second puck (100B) for the sake of clarity, is positionedupwardly within through bore (112) such that bottom surface (116) ofinsulated core (110) rests on or close to top surface (103) of base(102) of second puck (100B) with barrier film (122) disposed therebetween. As shown in FIG. 3, oblong-shaped protrusion (104) is sizedsuch that with first puck (100A) and second puck (100B) disposed withinthrough bore (112), barrier films (120, 122) are compressed between atop surface (107) of oblong-shaped protrusions (104) of pucks (100A,100B). It should be appreciated that with barrier films (120, 122)compressed between top surfaces (107) of oblong-shaped protrusions (104)of pucks (100A, 100B), wrinkles and/or creases in barrier films (120,122) will be minimized within this compressed area.

As shown in FIG. 3, oblong-shaped protrusions (104) of pucks (100A,100B), and in general puck (100), may further be sized such that withpucks (100A, 100B) disposed within through bore (112) of insulated core(110), an exterior surface (105) of oblong-shaped protrusions (104)rests on or close to an interior surface (113) of through bore (112).Thus, with first puck (100A) and second puck (100B) disposed withinthrough bore (112), exterior surfaces (105) of oblong-shaped protrusions(104) may compress barrier films (120, 122) between exterior surface(105) of oblong-shaped protrusions (104) and interior surface (113) ofthrough bore (112) to thereby minimize wrinkles and/or creases inbarrier films (120, 122) within this compressed area.

Also as shown in FIG. 3, oblong-shaped protrusions (104) of pucks (100A,100B), and in general puck (100), may further be sized such that withpucks (100A, 100B) disposed within through bore (112) of insulated core(110), top surfaces (103) of bases (102) of pucks (100A, 100B) rest onor close to top surface (114) of insulated core (110) and bottom surface(116) of insulated core (110) respectively. Thus, with first puck (100A)and second puck (100B) disposed within through bore (112), top surfaces(103) of bases (102) of pucks (100A, 100B) may compress barrier films(120, 122) between top surfaces (103) of bases (102) and top surface(114) of insulated core (110) and bottom surface (116) of insulated core(110) to thereby minimize wrinkles and/or creases in barrier films (120,122) within these compressed areas.

At this point, and as shown in FIG. 4A, insulated core (110) issubjected to a vacuum to evacuate insulated core (110) of gases withinany void spaces of insulated core (110) to thereby reduce heat transferacross insulated core (110). As insulated core (110) is subjected to avacuum, barrier films (120, 122) are heat sealed to thereby fluidly sealinsulated core (110) in the evacuated state. This evacuation and heatsealing may cause wrinkles and/or creases in barrier films (120, 122),however, as discussed above, pucks (100A, 100B) are configured tominimize wrinkles and/or creases in barrier films (120, 122) within theabove discussed compressed areas. Pucks (100A, 100B) are then removedfrom through bore (112) as shown in FIG. 4B, and barrier films (120,122) within through bore (112) are heat sealed to thereby form a fluidseal within through bore (112). Finally, excess material of barrierfilms (120, 122) is then removed to thereby define a seal (124)extending inwardly from interior surface (113) of through bore (112) anda seal (126) extending outwardly from insulated core (110) as shown inFIG. 4C.

II. Exemplary Alternative Puck to Reduce Wrinkles and/or Creases WithinVIP Barrier Films

FIGS. 5-10C illustrate a pair of exemplary alternative pucks (200, 300)and a method of using pucks (200, 300) to manufacture VIPs to avoidwrinkling and/or creasing of a barrier film used to enclose an insulatedcore. FIG. 5 shows a puck (200) having a base (202) and acircular-shaped protrusion (204) extending from a top surface (203) ofbase (202). Base (202) comprises a plurality of through bores (206).Although puck (200) of the present example comprises a circular-shapedprotrusion (204), it will be appreciated from the discussion below thatpuck (200) may comprise a protrusion having any other required shape(square, rectangular, triangular, etc.). FIG. 6 shows a puck (300)having a base (302) and a partial trapezoid-shaped protrusion (304)extending from a top surface (303) of base (302). Base (302) comprises aplurality of through bores (306). Although puck (300) of the presentexample comprises a trapezoid-shaped protrusion (304), it will beappreciated from the discussion below that puck (300) may comprise aprotrusion having any other required shape (square, rectangular,triangular, etc.).

FIGS. 7A-10C show the steps required to manufacture a VIP (230) usingpucks (200, 300). FIG. 7A shows a circular-shaped insulated core (210)having a pair of circular-shaped through bores (212, 214). Althoughinsulated core (210) of the present example is circular-shaped, itshould be understood that insulated core (210) may comprise any otherrequired shape (square, rectangular, triangular, etc.). Also, althoughinsulated core (210) of the present example comprises a pair ofcircular-shaped through bores (212, 214), it will be appreciated fromthe discussion below that through bores (212, 214) may comprise anyother required shape (square, rectangular, triangular, etc.).Circular-shaped insulated core (210) further comprises atrapezoid-shaped relief (216). Although insulated core (210) of thepresent example comprises a trapezoid-shaped relief (216), it will beappreciated from the discussion below that relief (216) may comprise anyother required shape (square, rectangular, triangular, etc.). As shownin FIG. 7B, a pair of barrier films (220, 222) are disposed adjacent toa top surface (218) and a bottom surface (219) of insulated core (210).

As shown in FIGS. 7C and 8, with barrier films (220, 222) disposedadjacent to top surface (218) and bottom surface (219) of insulated core(210), a first puck (200A), constructed according to the abovediscussion regarding puck (200) but referred to as first puck (200A) forthe sake of clarity, is positioned downwardly within through bore (212)such that top surface (203) of base (202) of first puck (200A) rests onor close to top surface (218) of insulated core (210) with barrier film(220) disposed there between. A second puck (200B), constructedaccording to the above discussion regarding puck (200) but referred toas second puck (200B) for the sake of clarity, is positioned upwardlywithin through bore (212) such that bottom surface (219) of insulatedcore (210) rests no or close to top surface (203) of base (202) ofsecond puck (200B) with barrier film (222) disposed there between. Atthe same time, a third puck (200C), constructed according to the abovediscussion regarding puck (200) but referred to as third puck (200C) forthe sake of clarity, is positioned downwardly within through bore (214)such that top surface (203) of base (202) of third puck (200C) rests onor close to top surface (218) of insulated core (210) with barrier film(220) disposed there between. A fourth puck (200D), constructedaccording to the above discussion regarding puck (200) but referred toas fourth puck (200D) for the sake of clarity, is positioned upwardlywithin through bore (214) such that bottom surface (219) of insulatedcore (210) rests on or close to top surface (203) of base (202) offourth puck (200D) with barrier film (222) disposed there between.

As shown in FIG. 8, circular-shaped protrusion (204) is sized such thatwith first puck (200A) and second puck (200B) disposed within throughbore (212), and with third puck (200C) and fourth puck (200D) disposedwithin through bore (214), barrier films (220, 222) are compressedbetween top surfaces (207) of circular-shaped protrusions (204) of pucks(200A, 200B, 200C, 200D). It should be appreciated that with barrierfilms (220, 222) compressed between top surfaces (207) ofcircular-shaped protrusions (204) of pucks (200A, 200B, 200C, 200D),wrinkles and/or creases in barrier films (220, 222) will be minimizedwithin this compressed area.

As shown in FIG. 8, circular-shaped protrusions (204) of pucks (200A,200B, 200C, 200D), and in general puck (200), may further be sized suchthat with pucks (200A, 200B, 200C, 200D) disposed within through bores(212, 214) of insulated core (210), an exterior surface (204) ofcircular-shaped protrusions (204) rests on or close to an interiorsurface (213) of through bore (212) and an interior surface (215) ofthrough bore (214). Thus, with first puck (200A) and second puck (200B)disposed within through bore (212), and with third puck (200C) andfourth puck (200D) disposed within through bore (214), exterior surfaces(205) of circular-shaped protrusions (204) may compress barrier films(220, 222) between exterior surface (205) of circular-shaped protrusions(204) and interior surfaces (213, 215) of through bores (212, 214) tothereby minimize wrinkles and/or creases in barrier films (120, 122)within this compressed area.

Also as shown in FIG. 8, circular-shaped protrusions (204) of pucks(200A, 200B, 200C, 200D), and in general puck (200), may further besized such that with pucks (200A, 200B, 200C, 200D) disposed withinthrough bores (212, 214) of insulated core (210), top surfaces (203) ofbases (202) of pucks (200A, 200B, 200C, 200D) rest on or close to topsurface (218) of insulated core (210) and bottom surface (219) ofinsulated core (210) respectively. Thus, with first puck (200A) andsecond puck (200B) disposed within through bore (212), and with thirdpuck (200C) and fourth puck (200D) disposed within through bore (214),top surfaces (203) of bases (202) of pucks (200A, 200B, 200C, 200D) maycompress barrier films (220, 222) between top surfaces (203) of bases(202) and top surface (218) of insulated core (210) and bottom surface(219) of insulated core (210) to thereby minimize wrinkles and/orcreases in barrier films (220, 222) within these compressed areas.

As shown in FIGS. 7C and 9, with barrier films (220, 222) disposedadjacent to top surface (218) and bottom surface (219) of insulated core(210), a first puck (300A), constructed according to the abovediscussion regarding puck (300) but referred to as first puck (300A) forthe sake of clarity, is positioned downwardly within relief (216) suchthat top surface (303) of base (303) of first puck (300A) rests on orclose to top surface (218) of insulated core (210) with barrier film(220) disposed there between. At the same time, a second puck (300B),constructed according to the above discussion regarding puck (300) butreferred to as second puck (300B) for the sake of clarity, is positionedupwardly within relief (216) such that bottom surface (219) of insulatedcore (210) rests on or close to top surface (303) of base (302) ofsecond puck (300B) with barrier film (222) disposed there between. Asshown in FIG. 9, trapezoid-shaped protrusion (304) is sized such thatwith first puck (300A) and second puck (300B) disposed within relief(216), barrier films (220, 222) are compressed between a top surface(307) of trapezoid-shaped protrusions (304) of pucks (300A, 300B). Itshould be appreciated that with barrier films (220, 222) compressedbetween top surfaces (307) of trapezoid-shaped protrusions (304) ofpucks (300A, 300B), wrinkles and/or creases in barrier films (220, 222)will be minimized within this compressed area.

As shown in FIG. 9, trapezoid-shaped protrusions (304) of pucks (300A,300B), and in general puck (300), may further be sized such that withpucks (300A, 300B) disposed within relief (216) of insulated core (210),an exterior surface (305) of trapezoid-shaped protrusions (304) rests onor close to an interior surface (217) of relief (216). Thus, with firstpuck (300A) and second puck (300B) disposed within relief (216),exterior surfaces (305) of trapezoid-shaped protrusions (304) maycompress barrier films (220, 222) between exterior surface (305) oftrapezoid-shaped protrusions (304) and interior surface (217) of relief(216) to thereby minimize wrinkles and/or creases in barrier films (220,222) within this compressed area.

Also as shown in FIG. 9, trapezoid-shaped protrusions (304) of pucks(300A, 300B), and in general puck (300), may further be sized such thatwith pucks (300A, 300B) disposed within relief (216) of insulated core(210), top surfaces (303) of bases (302) of pucks (300A, 300B) rest onor close to top surface (218) of insulated core (210) and bottom surface(219) of insulated core (210) respectively. Thus, with first puck (300A)and second puck (300B) disposed within relief (216), top surfaces (303)of bases (302) of pucks (300A, 300B) may compress barrier films (220,222) between top surfaces (303) of bases (302) and top surface (218) ofinsulated core (210) and bottom surface (219) of insulated core (210) tothereby minimize wrinkles and/or creases in barrier films (220, 222)within these compressed areas.

At this point, and as shown in FIG. 10A, insulated core (210) issubjected to a vacuum to evacuate insulated core (210) of gases withinany void spaces of insulated core (210) to thereby reduce heat transferacross insulated core (210). As insulated core (210) is subjected to avacuum, barrier films (220, 222) are heat sealed to thereby fluidly sealinsulated core (210) in the evacuated state. This evacuation and heatsealing may cause wrinkles and/or creases in barrier films (220, 222);however, as discussed above, pucks (200A, 200B, 200C, 200D, 300A, 300B)are configured to minimize wrinkles and/or creases in barrier films(220, 222) within the above discussed compressed areas. Pucks (200A,200B, 200C, 200D, 300A, 300B) are then removed from through bores (212,214) and relief (216) as shown in FIG. 10B, and barrier films (220, 222)within through bores (212, 214) and relief (216) are heat sealed tothereby form a fluid seal within through bores (212, 214) and relief(216). Finally, excess material of barrier films (220, 222) is thenremoved to thereby define a seal (224, 225) extending inwardly frominterior surfaces (213, 215) of through bores (212, 214) and a seal(226) extending inwardly from interior surface (217) of relief (216) andoutwardly from insulated core (210) as shown in FIG. 10C.

It should be understood that although the embodiments of pucks (100,200, 300) discussed above were discussed as being used in pairs, itshould be understood that in certain versions of VIPs (130, 230) it maybe desirable to use pucks (100, 200, 300) singularly. For instance,although VIPs (130, 230) discussed above are described as comprisingthrough bores (112, 212, 214) and/or relief (216) that pass completelythrough insulate cores (110, 210), it should be appreciated that arelief (not shown) may be formed in top surfaces (114, 218) and/orbottom surfaces (116, 219) of insulated cores (110, 210) that passesonly partially through insulated cores (110, 210). A single puck (100,200, 300) may then be positioned within this relief to thereby compressbarrier film against a bottom surface and/or interior side surfaces ofthe relief to thereby minimize wrinkles and/or creases in the barrierfilm within this relief.

Furthermore, protrusions (104, 204, 304) of pucks (100, 200, 300) may besufficiently thick to pass completely through through bores (112, 212,214) and/or relief (216) such that barrier film may be compressedbetween top surfaces (107, 207, 307) of protrusions (104, 204, 304) anda surface upon which insulated cores (110, 210) rest such that a singlepuck (100, 200, 300) may be used.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

I/We claim:
 1. A method of manufacturing a vacuum insulated panel, themethod comprising the steps of: (a) providing an insulated core having ashaped opening defined within the insulated core; (b) providing a firstpuck and a second puck; (c) positioning a first barrier film about a topsurface of the insulated core and a second barrier film about a bottomsurface of the insulated core; (d) disposing the first puck within theopening of the insulated core from a first side of the insulated core;(e) disposing the second puck within the opening of the insulated corefrom a second side of the insulated core; (f) evacuating the insulatedcore; (g) heat sealing the first barrier film and the second barrierfilm to thereby seal the insulated core in an evacuated state; and (h)removing the first puck and the second puck from the opening of theinsulated core.
 2. The method of claim 1, further comprising the step ofremoving excess barrier film of the first barrier film and the secondbarrier film from the shaped opening.
 3. The method of claim 1, whereinthe step of disposing the first puck within the opening of the insulatedcore from a first side of the insulated core and the step of disposingthe second puck within the opening of the insulated core from a secondside of the insulated core compresses the first barrier film and thesecond barrier film together within the opening of the insulated core.4. The method of claim 1, wherein the step of disposing the first puckwithin the opening of the insulated core from a first side of theinsulated core and the step of disposing the second puck within theopening of the insulated core from a second side of the insulated corecompresses the first barrier film and the second barrier film againstthe top surface and the bottom surface of the insulated core.
 5. Themethod of claim 1, wherein the step of disposing the first puck withinthe opening of the insulated core from a first side of the insulatedcore and the step of disposing the second puck within the opening of theinsulated core from a second side of the insulated core compresses thefirst barrier film and the second barrier film against an interiorsurface of the opening of the insulated core.
 6. The method of claim 1,further comprising the step of providing the first puck with a shapedportion and the second puck with a shaped portion.
 7. The method ofclaim 1, further comprising the step of providing the first puck with ashaped portion comprising an exterior surface correlating to a shape ofan interior surface of the opening of the insulated core and the secondpuck with a shaped portion comprising an exterior surface correlating tothe shape of the interior surface of the opening of the insulated core.8. The method of claim 1, further comprising the step of providing thefirst puck with a shaped portion comprising an exterior surface sizedsubstantially similarly to an interior surface of the opening of theinsulated core and the second puck with a shaped portion comprising anexterior surface sized substantially similarly to the interior surfaceof the opening of the insulated core.
 9. An apparatus for minimizingwrinkles and/or creases in barrier film of a vacuum insulated panel, theapparatus comprising: (a) a first puck, wherein the first puckcomprises: (i) a base, wherein the base of the first puck comprises atop surface and a bottom surface, and (ii) a protrusion, wherein theprotrusion of the first puck extends from the top surface of the base ofthe first puck, wherein the protrusion of the first puck comprises a topsurface and an exterior surface, wherein the exterior surface of theprotrusion of the first puck defines a first shape; and (b) a secondpuck, wherein the second puck comprises: (i) a base, wherein the base ofthe second puck comprises a top surface and a bottom surface, and (ii) aprotrusion, wherein the protrusion of the second puck extends from thetop surface of the base of the second puck, wherein the protrusion ofthe second puck comprises a top surface and an exterior surface, whereinthe exterior surface of the protrusion of the second puck defines asecond shape; wherein the first puck and the second puck are orientedsuch that at least one barrier film is configured to be compressedbetween the top surface of the protrusion of the first puck and the topsurface of the protrusion of the second puck to thereby minimizewrinkles and/or creases within the at least one barrier film.
 10. Theapparatus of claim 9, wherein the first shape and the second shapecomprise the same shape.
 11. The apparatus of claim 9, wherein theprotrusion of the first puck and the protrusion of the second puck eachdefine an interior void.
 12. The apparatus of claim 9, wherein the firstshape and the second shape correlate to the shape of an opening intowhich the first puck and the second puck are inserted.
 13. The apparatusof claim 9, wherein the top surface of the base of the first puck andthe top surface of the base of the second puck are configured tocompress the at least one barrier film between the top surfaces and atleast one other surface.
 14. The apparatus of claim 9, wherein theexterior surface of the protrusion of the first puck and the exteriorsurface of the protrusion of the second puck are configured to compressthe at least one barrier film between the exterior surfaces and at leastone other surface.
 15. The apparatus of claim 9, wherein the at leastone barrier film comprises a first barrier film and a second barrierfilm.
 16. The apparatus of claim 9, wherein the first shape and thesecond shape comprise an oblong.
 17. The apparatus of claim 9, whereinthe first shape and the second shape comprise a circle.
 18. Theapparatus of claim 9, wherein the first shape and the second shapecomprise a partial trapezoid.
 19. A method of manufacturing a vacuuminsulated panel, wherein at least one puck comprises a base comprising atop surface and a bottom surface and a protrusion extending from the topsurface of the base, wherein the protrusion comprises a top surface andan exterior surface, the method comprising the steps of: (a) providingan insulated core having at least one opening defined within theinsulated core; (b) disposing at least one barrier film about theinsulated core; (c) disposing the protrusion of the at least one puckwithin the at least one opening of the insulated core; (d) subjectingthe insulated core to a vacuum; (e) heat sealing the at least onebarrier film to thereby seal the insulated core in an evacuated state;(f) removing the at least one puck from the at least one opening of theinsulate core; and (g) removing excess barrier film of the at least onebarrier film.
 20. The method of claim 19, wherein the at least one puckcomprises at least a first puck and a second puck, wherein the step ofdisposing the protrusion of the at least one puck within the opening ofthe insulated core comprises the further step of disposing a protrusionof the first puck within a first side of the opening and disposing aprotrusion of the second puck within a second side of the opening.